complete brake systems - carlisle brake & friction

Boosters

Complete Brake SystemsCarlisle offers proven brake system designs for a wide range of off-highway vehicles and equipment from the foot pedal to the hydraulic actuator to the brake — including the friction material. We design and build dry disc caliper brakes, drum brakes and mechanical brakes for both service and park applications. When you specify a Carlisle brake system you can count on smooth, quiet and dependable stopping power. In addition, now many of our brakes are manufactured in our Hangzhou, China plant... ensuring you get the most cost effective, highest quality brake system in the world.

Carlisle Benefits• Complete brake systems — hydraulic controls,

service brakes, park brakes and friction• Proven OE supplier for over 50 years• Manufacturing and engineering support in Asia,

US and Europe• All designs comply with SAE brake

and ISO requirements• Clean sheet or modified standard designs• Quick turn prototypes• Extensive product testing ensures robost

performance and reliability in service• Maintenance of an inventory of service parts for

all brakes we manufacture

Partner to oeMs around the WorldSince our introduction of a caliper disc park brake more than 50 years ago, we’ve been a key partner to most of the off-highway industry’s major OEMs. Our organization is well positioned to provide global customer support, including manufacturing, logistics and service. Carlisle is an experienced supplier of complete brake solutions that OEMs around the world can count on for high performance braking.

2

CBF Hangzhou, China

CBF Pontypool, UK

CBF World Headquarters, Solon, OH USA

CBF Bloomington, IN USA

Boosters Provide a higher outPut Pressure to the Brake systeM resulting in

A significant reduction in pedal effort and pedal travel to achieve the required operating pressure at the brake.

A progressive and controllable braking response offering improved cabin ergonomics and enhanced operator comfort.

A more efficient method of applying the brakes on Off-Highway vehicles.

Boosters require much less input force to achieve Normal operating Pressure Boosted Master Cylinder PerforManCe

Input Force v Output Pressure120

110

100

90

80

70

60

50

40

30

20

10

00 200 400 600 800 1000 1200 1400 1600 1800 2000

BOOster Knee Point27mm Ø Master Cylinder

outP

ut P

ress

ure

to B

rake

(Bar

)

27mm ØBOOster

31.75mm Ø BOOster

27mm Ø Master Cylinder31.75mm Ø Master Cylinder

BOOster Knee Point 31.75mm Ø Master Cylinder

25 bar Boostsupply Pressure normal operating Pressurenormal operating Pressure

Boost ratio 6.2 : 1 5 : 1 4 : 1 Master Cylinder27mm Ø BOOster31.75mm Ø BOOster

25.4mm Ø M/Cyl 27mm Ø M/Cyl 31.75mm BOOster4:1 boost ratio

to achieve the same Pedal Force a Carlisle Booster requires much less pedal travel than a standard master cylinder.

Pedal forCe vs Pedal traVel Prediction based on 6:1 pedal ratio with a fluid volumetric displacement of 16cc / brake.

Pedal forCe (n)

250

200

150

100

50

0

0 100 200 300 400 500 600 700 800

inPut forCe (n)

Peda

l tr

aVel

(mm

)

MIDI tWIN Booster

CoMPACt tWIN Booster

Drivers demand ‘Luxury Car’ performance from brake & clutch systems for off-Highway vehicles

Increasing horsepower, speed and weight requirements in europe and North America have led to;

truck legislation imposed on vehicles operating at > 50kph

Increasing brake running clearance reduces brake drag, resulting in improved fuel efficiency and lower operating costs

Braking required on all four wheels

Balanced braking across axles

3

Why Use a Boosted Master Cylinder (Booster) Instead of a Standard Master Cylinder?

Export Product and Technology Trends

www.CarlisleCBF.com

Gr

os

s V

eH

ICLe

We

IGH

t (k

G)

COMPACt BOOster

MIdI BOOster

MAster CylInders

Application Ranges

Braking System Diagrams tyPiCal traCtor Braking systeM

Carlisle tWin Booster aPPliCation Carlisle tandeM tWin Booster aPPliCation

rear Wheel Brake

slave cylinder

supply Pressure supply Pressure

oil tank

oil tank

twin Pedals

rear Wheel Brake

rear Wheel Brake

trailer Braketrailer Brake lights

reservoir

Compact twin Booster

tandem twin Booster

front Wheel Brake

Master Cylinders

120—300+ HP

80—140 HP

50—100 HP

BOOSTERS

4

Most tractor brake systems use MINerAL oil, but some use VeGetABLe (Glycol) synthetic fluid as used by passenger cars — it is very important that the seals of either are not mixed

2500HorsePoWer

10000+

Applications

Trailer Brake

Compact Twin BOOStEr

Compact Single BOOStEr

MIDI twin BOOStEr

Tandem Twin BOOStEr

Master Cylinder

tandem Single BOOStEr

BOOSTERS

5www.CarlisleCBF.com

MIDI tWIN Booster

tANDeM tWIN Booster tANDeM sINGLe Booster MAster CyLINDer

CoMPACt sINGLe Booster

CoMPACt tWIN Booster

A wide range of boost ratios and master cylinder diameters can be used to tailor the performance to meet the customer's exact requirements.Provides a progressive and controllable braking response by optimising the “pedal feel” and improving driver comfort and cabin ergonomics.Use of PtFE seal technology provides high wear resistance and extended durability life. One million cycles achieved with no deterioration of product.Self-bleed feature allows any air ingress in the master cylinders to be vented to the tank chamber during normal operation.No additional reservoir required: The master cylinder and BOOStEr use a common oil supply thus preventing the cross contamination of fluids or potential ingress of debris.Significant reduction in warranty issues.Closed centre BOOStEr design minimizes oil usage.Uses the existing vehicle power hydraulic system to provide servo assist to the master cylinder.Patented design for twin or single pedal brake systems.Significant cost advantage compared to Power Valve products.Ease of installation — only four hydraulic connections required. Various mounting plate and push rod options available.

Benefits of a Carlisle BOOSTER

6

BOOSTERS

Comfort & Safety

COMPACT TWIN BOOSTER

129

4642

.5

60

203 *

sPeCifiCations Body length Less than 205mm range of diameters 25.4 to 57mm

oil Mineral Oil supply Pressure 15 bar to 40 bar

tested to 1,000,000 Cycles Minimum flow rate 10L / min

Booster ratio 2.65, 4, 5 and 6.2:1 operation temperature -30°C to 100°C

Patented closed circuit design with integrated master cylinder BOOster and reservoir in a single component.» Patented design for mineral oil twin pedal braking systems providing a

boosted, progressive pedal feel.Generic design enables performance to be easily matched to most »agricultural and industrial vehicle applications.Self-bleed design keeps » BOOStEr purged of any ingressed air.PTFE seal technology » ensures extended service life.No reservoir required — uses supply oil for braking systems. »range of metric or imperial ports — to international standards — available. »

» Large variety of pushrod lengths and thread sizes available. * » Clevis options available to suit customer requirements.

7

BOOSTERS

www.CarlisleCBF.com

COMPACT SINGLE BOOSTERPatented closed circuit design with integrated master cylinder, BOOster and reservoir in a single component.

Patented design for mineral oil single pedal braking systems, providing a » boosted, progressive pedal feel.

» Ideal for clutch applications.» Generic design enables performance to be easily matched to most

agricultural and industrial vehicle applications.» Self-bleed design keeps BOOStEr purged of any ingressed air.

» PtFE seal technology ensures extended service life.

» No reservoir required — uses supply oil for braking or clutch systems. » range of metric or imperial ports — to international standards — available.

» Large variety of pushrod lengths and thread sizes available. * » Clevis options available to suit customer requirements.

ø70

5247

192 *




Booster ratio 2.65, 4, 5 and 6.2:1 operation temperature -30°C to 100°C

8

BOOSTERS

*174 124

6044

.535

.4

simplified design reduced weight and smaller size give cost advantages over larger BOOsters in the Carlisle BOOster family.» Patented design for mineral oil twin pedal braking systems providing a

boosted, progressive pedal feel.

» Generic design enables performance to be easily matched to mostagricultural and industrial applications.

» Self-bleed design keeps BOOStEr purged of any ingressed air.

» PtFe seal technology ensures extended service life.

» No reservoir required — uses supply oil for braking systems.

» range of metric or imperial ports — to international standards — available.» Large variety of pushrod lengths and thread sizes available. * » Clevis options available to suit customer requirements.

sPeCifiCations Body length Less than 175mm supply Pressure 15 bar to 40 bar

oil Mineral Oil Minimum flow rate 10L / min

tested to 1,000,000 Cycles operation temperature -30°C to 100°C

Booster ratio 3, 4 and 5:1 Vehicle Horsepower* 80 HP to 130 HP

range of diameters 25.4 to 30mm *Additional Feature

MIDI TWIN BOOSTER

9

BOOSTERS

www.CarlisleCBF.com




Booster ratio 2.65, 4, 5, and 6:1 operation temperature -30°C to 100°C

TANDEM TWIN BOOSTERBraking CaPaBilities:• Pressure Balanced • Independent • dual-circuit• designed for twin pedal vehicles with four independent brakes

roviding a boosted, »with trailer brake option.Patented design for mineral oil twin pedal braking systems p progressive pedal feel.Generic design enables performance to be easily matched to most agricultural »and industrial vehicle applications.

» Self-bleed design keeps BOOStEr purged of any ingressed air.

» PtFE seal technology ensures extended service life.

» No reservoir required — uses supply oil for braking systems.

» range of metric or imperial ports — to international standards — available.» Large variety of push rod lengths and thread sizes available. * » Clevis options available to suit customer requirements.

129

60

4642

.5

229 *

10

BOOSTERS




Booster ratio 3, 4 and 5:1 operation temperature -30°C to 100°C

TANDEM SINGLE BOOSTERBraking CaPaBilities:• Independent • dual-circuit• »designed for single pedal vehicles with split circuit braking.Patented design for mineral oil single pedal braking systems providing aboosted, progressive pedal feel.

Generic design enables performance to be easily matched to most construction »and industrial vehicle applications.Self-bleed design keeps » BOOStEr purged of any ingressed air.PtFE seal technology ensures extended service life. »No reservoir required — uses supply oil for braking systems. »range of metric or imperial ports — to international standards — available. »

» Large variety of push rod lengths and thread sizes available. * » Clevis options available to suit customer requirements.

ø70

5646

216.5 *


BOOSTERS

MASTER CYLINDER» Designs for single and twin pedal applications.» Twin pedal cylinders feature proven compensation design for dual circuit

pressure balance.» New self-bleed design features PtFE sealing for improved life and

continuous air expulsion.» Designed to meet a range of operating pressures and temperatures.» Large variety of pushrod lengths and thread sizes. *» range of metric or imperial ports — to international standards — available. » Clevis options available to suit customer requirements.

sPeCifiCations oil Mineral and Glycol (DOt3,4) range of diameters 15.8 to 31.75mm

148.5

123.5

49

60.4

4834

.539

*

*

12

BOOSTERS

Booster Capability Integrated Integrated Integrated Integrated Integratedrequires separate system

Boost ratio available 2.6, 4.0, 5.0 and 6.2:1

2.6, 4.0, 5.0 and 6.2:1

3.2, 4.0 and 5.2:1

2.6, 4.0, 5.0 and 6.2:1

3, 4, 5:1 Not Applicable

Master Cyl diameter 27.0, 31.75 and 57.0

31.75, 35.0 and 41.0

25.4, 27.0 and 30.0

35 25.4, 4415.8, 19.0, 22.2, 25.4, 27.0

Master Cyl stroke 35.0 and 30.0 35 32 35 17.5 / 17.5 35

Master Cyl displacement available (cc)

20.0, 27.0 and 76.0

27.0, 33.0 and 45.0

15.1, 17.1 and 21.1

Variable, dependant on Front / rear requirements

24.3 / 24.36.85, 9.91, 13.05, 17.75, 20.02

Compensation available (%)

25% to 50% and 100%

N/A 100% only

Variable, dependant on Front / rear requirements

N/A N/A

length mm 202 192 175 230 220 Various

Closed Circuit

reservoir required

Closed Center

simple installation

steer turn facility

Modular design

reduced system Complexity

self-Bleed

glycol (dot4) / Mineral oil

Mineral Mineral Mineral Mineral MineralMineral / Glycol (DOt4)


CoMPaCt twin Booster

CoMPaCt single Booster

Midi twin Booster

tandeM twin Booster

tandeM single Booster

Master Cylinder

PRODUCT OVERVIEWBOOSTERS

Carlisle Brake and Friction 6180 Cochran Rd.Solon, OH 44139Phone: 1-855-403-9083 Email: [email protected] Visit us online @ www.CarlisleCBF.com

Carlisle...Your Global ResourceToday, more than ever, it is imperative that suppliers are prepared to support their customersaround the world. Carlisle Brake & Friction has established a network of manufacturing anddistribution facilities around the globe that give us a presence in the world’s fastest growingmarkets. This commitment to the global marketplace makes Carlisle the right choice for yournew brake or friction design, no matter where you are or what you want to be.




Today, more than ever, it is imperative that suppliers are prepared to support their customers around the world. Carlisle Brake & Friction has established a network of manufacturing and distribution facilities around the globe that give us a presence in the world’s fastest growing markets. This commitment to the global marketplace makes Carlisle the right choice for your new brake or friction design, no matter where you are or what you want to be.

Carlisle...Your Global ResourceCarlisle...Your Global ResourceToday, more than ever, it is imperative that suppliers are prepared to support their customersaround the world. Carlisle Brake & Friction has established a network of manufacturing anddistribution facilities around the globe that give us a presence in the world’s fastest growingmarkets. This commitment to the global marketplace makes Carlisle the right choice for yournew brake or friction design, no matter where you are or what you want to be.

EXPERIENCED. GLOBAL . INNOVAT IVE .

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